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EP2173793A2 - Masterbatch preparation process - Google Patents

Masterbatch preparation process

Info

Publication number
EP2173793A2
EP2173793A2 EP08826293A EP08826293A EP2173793A2 EP 2173793 A2 EP2173793 A2 EP 2173793A2 EP 08826293 A EP08826293 A EP 08826293A EP 08826293 A EP08826293 A EP 08826293A EP 2173793 A2 EP2173793 A2 EP 2173793A2
Authority
EP
European Patent Office
Prior art keywords
wax
blend
masterbatch
mass
polymer
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP08826293A
Other languages
German (de)
French (fr)
Other versions
EP2173793B1 (en
Inventor
Lionel Nicholas Mantzivis
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Priority to PL08826293T priority Critical patent/PL2173793T3/en
Publication of EP2173793A2 publication Critical patent/EP2173793A2/en
Application granted granted Critical
Publication of EP2173793B1 publication Critical patent/EP2173793B1/en
Not-in-force legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J3/00—Processes of treating or compounding macromolecular substances
    • C08J3/20—Compounding polymers with additives, e.g. colouring
    • C08J3/22—Compounding polymers with additives, e.g. colouring using masterbatch techniques
    • C08J3/226—Compounding polymers with additives, e.g. colouring using masterbatch techniques using a polymer as a carrier
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2/00—Processes or devices for granulating materials, e.g. fertilisers in general; Rendering particulate materials free flowing in general, e.g. making them hydrophobic
    • B01J2/22—Processes or devices for granulating materials, e.g. fertilisers in general; Rendering particulate materials free flowing in general, e.g. making them hydrophobic by pressing in moulds or between rollers
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2491/00—Characterised by the use of oils, fats or waxes; Derivatives thereof

Definitions

  • the invention relates to the preparation of a masterbatch for use in plastics manufacture, for example, moulding and extruding.
  • Plastics have a wide use and there are many types of industries from liquid containers to fibres. Many of the products are used in the fast moving consumer industry and require colour for visual presentation.
  • the ideal properties of the pigment are for a high dispersion in the base material, common problems are that the pigment or other materials are subject to high temperatures as well as high pressures to combine them, as well as high sheet in the initial stages, this leads to degradation of the material as well as reagromalation of the pigment.
  • Dispersion is therefore reduced due to the non-uniform particle size in the material i.e., a mix with a one micron particle size ends up with a percentage of higher micro particles, thus affecting the final distribution.
  • the final colour, tint strength are affected by these various processes.
  • the invention provides a masterbatch preparation process, said process including: blending one or more of a molten wax and a non-wax polymer, and one or more additives; tempering the blend or cooling the blend to just above the congealing point thereof; solidifying the blend by cooling; and comminuting said solidified blend.
  • the non-wax polymer may have a congealing point and a melting point within 10 0 C
  • the polymer congealing and melting points may be within 5 0 C.
  • the additive may be a polymer.
  • the polymer may be an elastomer, a plasticiser, EVOH, EVA, or the like.
  • the blend may include another polymer besides the molten wax.
  • This polymer may have a substantially higher melting point and be in particulate form during the blending.
  • the solidifying may be achieved by dispensing the blend onto a cooled surface.
  • the cooled surface may be a chilled dimpled roller surface whereby upon solidifying dimple sized pellets of the blend are formed.
  • the solidified blend may be scraped from the roller surface.
  • the pellets which have been released from the roller surface may be milled or ground to form fine particles of the solidified blend which are useable as a masterbatch.
  • the additives may be selected from pigments and filler material.
  • the filler material may be calcium or other inorganic material.
  • the blend may include a powdered additive.
  • the blend may include a liquid additive.
  • the blend may include fiber which is dispersed into the masterbatch.
  • the blend may be a dry blend of additives with a polymer and a wax.
  • the wax may have a narrow carbon number range spread.
  • the wax may have a substantially constant melting point.
  • the wax may be a modified wax, for example oxidized or functionalized, natural wax, or a speciality wax such as a aminde or metallocene wax, or a blend thereof.
  • the wax may be a non-polar wax.
  • the wax may be a polar wax such as a polyethylene wax.
  • the wax may be a paraffin wax, micro-crystalline wax, polyethylene, and/or polypropylene wax.
  • the wax may be a Fischer-Tropsch wax.
  • the additives may include one or more of calcium carbonate, titanium, pigment, or the like.
  • the process may include homogenizing one or more of the blend components.
  • the process may include homogenizing and dispersing wax into a polymer to form a carrier.
  • the process may include homogenizing and dispersing wax into a polymer to form a mixture.
  • the process may include homogenizing and dispersing liquid additive into wax and/or polymer to form a mixture.
  • the process may include homogenizing and dispersing powdered additive into wax and/or polymer to form a mixture.
  • the process may include homogenizing and dispersing fiber into wax and/or polymer to form a mixture.
  • the process may include drying the blend prior to the wax being melted.
  • the blending may take place in a heated blender.
  • the process is carried out a low pressure, typically without any overpressure i.e. at normal atmospheric conditions wherever the process is being carried out. This is unlike current processes which employ high pressures in extruders and the like to combine the masterbatch ingredients.
  • the process may produce a masterbatch including 40 mass% titanium dioxide. This masterbatch is believed to have the same whitening effectiveness as a 75 mass% titanium dioxide masterbatch using conventional preparation processes.
  • the process may produce a masterbatch including in excess of 80 mass% titanium dioxide, typically in excess of 90 mass%.
  • the process is carried out at low temperatures, typically below 100 0 C.
  • the process is a low shear process for preparing the masterbatch.
  • the masterbatch product may be in the form of prills, flakes, granules, a powder, or the like.
  • the masterbatch may contain from 1 mass% to 99 mass% wax.
  • the masterbatch may contain from 1 mass% to 99 mass% polymer.
  • the powdered additive may be selected from calcium carbonate, talc, titanium dioxide, antimony, or the like.
  • the fiber in the masterbatch may be selected from natural and synthetic fibers, for example, glass, carbon fiber, and wood.
  • Fig 1 shows a diagrammatic flow diagram of a masterbatch process of the invention.
  • the process of the present invention as illustrated in Fig 1 provides a novel way of producing a masterbatch or polymer improver by heating a wax or polymer with a low temperature and mixing the molten wax with a additives, including pigments, at a low temperature above the congealing point of the wax to create a carrier material, in doing so this process will not degrade the pigment or additive which will be mixed together.
  • the process includes blending a molten wax from reservoir B with one or more additives from additive tanks A in a heated or insulated blender C, whereafter the blend is cooled in a cooling tank D to just above the congealing point thereof.
  • the cooled blend may be termed a tempered blend, is then solidified by cooling on a dimpled chilled roller E from which the solidified blend is scraped and the particles are taken by a conveyer belt F to a milling device G where it is milled or ground to form flakes or prills of the desired size.
  • a liquid pigment can be added and blended which will have a very high dispersion, but in its liquid form difficult to add to a polymer in a production process.
  • a liquid pigment and then solidified allows for a means of having the properties of a liquid pigment in solid form which can be used in a more user friendly means.
  • a uniform base carrier material is first produced, this can be fed to a number of secondary mixing units where the additives are uniformly mixed with their own properties, for instance, one secondary mixing unit might be mixing a liquid pigment while another could be mixing a white colour and a third a calcium carbonate.
  • the process uses a wax, a modified wax (oxidized, functionalized), natural wax and/or specialty wax (amide, metallocene, etc.,) all can be used in this approach as well as blended waxes or waxes blended with polymers or polymer blend.
  • Fischer-Tropsch waxes are desirable as they have many desirable properties some of which have very high purity being essentially free of any sulphur, nitrogen and aromatic species and have high normal paraffin content. Another desirable property of Fischer- Tropsch waxes is their opacity, i.e., their lack of translucent appearance.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Organic Chemistry (AREA)
  • Health & Medical Sciences (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Processes Of Treating Macromolecular Substances (AREA)
  • Compositions Of Macromolecular Compounds (AREA)
  • Processing And Handling Of Plastics And Other Materials For Molding In General (AREA)

Abstract

The process of the present invention provides a novel way of producing a masterbatch or polymer improver by heating a wax or polymer with a low temperature and mixing the molten wax with additives, including pigments, at a low temperature above the congealing point of the wax to create a carrier material, in doing so this process will not degrade the pigment or additive which will be mixed together.

Description

MASTERBATCH PREPARATION PROCESS
Field of the Invention
The invention relates to the preparation of a masterbatch for use in plastics manufacture, for example, moulding and extruding.
Background to the Invention
Plastics have a wide use and there are many types of industries from liquid containers to fibres. Many of the products are used in the fast moving consumer industry and require colour for visual presentation.
It is the masterbatch industry that supplies the colour additives to the plastic industry and the pigment is commonly suspended in a polymer. Masterbatch manufacturers use high speed mixers or internal mixers to first mix the pigment and this is then fed through an extruder with high temperatures and high pressures to combine the pigments and the carrier and to form a granule.
The ideal properties of the pigment are for a high dispersion in the base material, common problems are that the pigment or other materials are subject to high temperatures as well as high pressures to combine them, as well as high sheet in the initial stages, this leads to degradation of the material as well as reagromalation of the pigment.
Dispersion is therefore reduced due to the non-uniform particle size in the material i.e., a mix with a one micron particle size ends up with a percentage of higher micro particles, thus affecting the final distribution. The final colour, tint strength are affected by these various processes. Summary of the Invention
The invention provides a masterbatch preparation process, said process including: blending one or more of a molten wax and a non-wax polymer, and one or more additives; tempering the blend or cooling the blend to just above the congealing point thereof; solidifying the blend by cooling; and comminuting said solidified blend.
The non-wax polymer may have a congealing point and a melting point within 10 0C
The polymer congealing and melting points may be within 5 0C.
The additive may be a polymer.
The polymer may be an elastomer, a plasticiser, EVOH, EVA, or the like.
The blend may include another polymer besides the molten wax. This polymer may have a substantially higher melting point and be in particulate form during the blending.
The solidifying may be achieved by dispensing the blend onto a cooled surface.
The cooled surface may be a chilled dimpled roller surface whereby upon solidifying dimple sized pellets of the blend are formed.
The solidified blend may be scraped from the roller surface. The pellets which have been released from the roller surface may be milled or ground to form fine particles of the solidified blend which are useable as a masterbatch.
The additives may be selected from pigments and filler material.
The filler material may be calcium or other inorganic material.
The blend may include a powdered additive.
The blend may include a liquid additive.
The blend may include fiber which is dispersed into the masterbatch.
The blend may be a dry blend of additives with a polymer and a wax.
The wax may have a narrow carbon number range spread.
The wax may have a substantially constant melting point.
The wax may be a modified wax, for example oxidized or functionalized, natural wax, or a speciality wax such as a aminde or metallocene wax, or a blend thereof.
The wax may be a non-polar wax.
The wax may be a polar wax such as a polyethylene wax. The wax may be a paraffin wax, micro-crystalline wax, polyethylene, and/or polypropylene wax.
The wax may be a Fischer-Tropsch wax.
The additives may include one or more of calcium carbonate, titanium, pigment, or the like.
The process may include homogenizing one or more of the blend components.
The process may include homogenizing and dispersing wax into a polymer to form a carrier.
The process may include homogenizing and dispersing wax into a polymer to form a mixture.
The process may include homogenizing and dispersing liquid additive into wax and/or polymer to form a mixture.
The process may include homogenizing and dispersing powdered additive into wax and/or polymer to form a mixture.
The process may include homogenizing and dispersing fiber into wax and/or polymer to form a mixture.
The process may include drying the blend prior to the wax being melted. The blending may take place in a heated blender.
The process is carried out a low pressure, typically without any overpressure i.e. at normal atmospheric conditions wherever the process is being carried out. This is unlike current processes which employ high pressures in extruders and the like to combine the masterbatch ingredients.
The process may produce a masterbatch including 40 mass% titanium dioxide. This masterbatch is believed to have the same whitening effectiveness as a 75 mass% titanium dioxide masterbatch using conventional preparation processes.
The process may produce a masterbatch including in excess of 80 mass% titanium dioxide, typically in excess of 90 mass%.
The process is carried out at low temperatures, typically below 1000C.
The process is a low shear process for preparing the masterbatch.
The masterbatch product may be in the form of prills, flakes, granules, a powder, or the like.
The masterbatch may contain from 1 mass% to 99 mass% wax.
The masterbatch may contain from 1 mass% to 99 mass% polymer.
The powdered additive may be selected from calcium carbonate, talc, titanium dioxide, antimony, or the like. The fiber in the masterbatch may be selected from natural and synthetic fibers, for example, glass, carbon fiber, and wood.
Description of Embodiments of the Invention
The invention will now be described, by way of non-limiting example only, with reference to the accompanying diagrammatic drawing.
In the drawing,
Fig 1 shows a diagrammatic flow diagram of a masterbatch process of the invention.
In the Figure,
A Additive addition
B Molten wax reservoir
C Blender
D Tempering/Cooling device
E Dimpled roller F Conveyer Belt Comminution/Grinding/Milling
H Cross section of mould belt
The process of the present invention as illustrated in Fig 1 provides a novel way of producing a masterbatch or polymer improver by heating a wax or polymer with a low temperature and mixing the molten wax with a additives, including pigments, at a low temperature above the congealing point of the wax to create a carrier material, in doing so this process will not degrade the pigment or additive which will be mixed together.
The process includes blending a molten wax from reservoir B with one or more additives from additive tanks A in a heated or insulated blender C, whereafter the blend is cooled in a cooling tank D to just above the congealing point thereof. The cooled blend, may be termed a tempered blend, is then solidified by cooling on a dimpled chilled roller E from which the solidified blend is scraped and the particles are taken by a conveyer belt F to a milling device G where it is milled or ground to form flakes or prills of the desired size.
What is also unique is that a liquid pigment can be added and blended which will have a very high dispersion, but in its liquid form difficult to add to a polymer in a production process. As the process defined herein allows for the use of a liquid pigment and then solidified allows for a means of having the properties of a liquid pigment in solid form which can be used in a more user friendly means.
A common misconception for instance, in a white masterbatch, is that the higher the titanium dioxide content the better the product. This can be false, due to the high compacting and inadequate wetting out of the titanium dioxide the particle size is not uniform which leads to inferior dispersion as to the process mentioned here with less titanium.
This can have a cost implication, as well as technical. Due to the higher loading and because the titanium dioxide is usually more expensive than the carrier, the final product becomes more expensive with the same or lower dispersion than with the process outlined here.
The process outlined herein with a 50 % loading, performs the same, if not better than commonly manufactured products with a greater than 50 % loading, therefore resulting in less use of masterbatch.
In colours, this difference becomes more pronounced.
Because a uniform base carrier material is first produced, this can be fed to a number of secondary mixing units where the additives are uniformly mixed with their own properties, for instance, one secondary mixing unit might be mixing a liquid pigment while another could be mixing a white colour and a third a calcium carbonate.
The process uses a wax, a modified wax (oxidized, functionalized), natural wax and/or specialty wax (amide, metallocene, etc.,) all can be used in this approach as well as blended waxes or waxes blended with polymers or polymer blend.
Fischer-Tropsch waxes are desirable as they have many desirable properties some of which have very high purity being essentially free of any sulphur, nitrogen and aromatic species and have high normal paraffin content. Another desirable property of Fischer- Tropsch waxes is their opacity, i.e., their lack of translucent appearance.

Claims

Claims
1. A masterbatch preparation process, said process including: blending one or more of a molten wax and a non-wax polymer, and one or more additives; tempering the blend or cooling the blend to just above the congealing point thereof; solidifying the blend by cooling; and comminuting said solidified blend.
2. A process as claimed in claim 1 , wherein the blend includes another polymer besides the molten wax, which polymer has a substantially higher melting point and is in particulate form during the blending.
3. A process as claimed in claim 1 or claim 2, wherein the solidifying is achieved by dispensing the blend onto a cooled surface.
4. A process as claimed in claim 3, wherein the cooled surface is a chilled dimpled roller surface whereby upon solidifying dimple sized pellets of the blend are formed.
5. A process as claimed in claim 4, wherein the pellets are milled or ground to form fine particles of the solidified blend which are useable as a masterbatch.
6. A process as claimed in any one of the preceding claims, wherein the additives are selected from polymers, pigments, and filler material.
7. A process as claimed in any one of the preceding claims, wherein the blend includes fiber which is dispersed into the masterbatch.
8. A process as claimed in any one of the preceding claims, wherein the wax has a substantially constant melting point.
9. A process as claimed in claim 8, wherein the wax is a modified wax, functionalized, natural wax, or a speciality wax, or a blend thereof.
10. A process as claimed in claim 8, wherein the wax is a Fischer-Tropsch wax.
11. A process as claimed in any one of the preceding claims, wherein the additives include one or more of calcium carbonate, titanium, and pigment.
12. A process as claimed in claim 1 , which produces a masterbatch including at least 40 mass% titanium dioxide.
13. A process as claimed in claim 12, wherein the process produces a masterbatch including in excess of 80 mass% titanium dioxide, typically in excess of 90 mass%.
14. A process as claimed in any one of the preceding claims, which process is carried out at low temperatures of below 1000C.
15. A process as claimed in any one of the preceding claims, wherein the masterbatch contains from 1 mass% to 99 mass% wax.
16. A process as claimed in any one the preceding claims 2 to 15, wherein the masterbatch contains from 1 mass% to 99 mass% polymer.
EP08826293.6A 2007-07-10 2008-08-26 Masterbatch preparation process Not-in-force EP2173793B1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PL08826293T PL2173793T3 (en) 2007-07-10 2008-08-26 Masterbatch preparation process

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
ZA200705644 2007-07-10
PCT/ZA2008/000077 WO2009009808A2 (en) 2007-07-10 2008-08-26 Masterbatch preparation process

Publications (2)

Publication Number Publication Date
EP2173793A2 true EP2173793A2 (en) 2010-04-14
EP2173793B1 EP2173793B1 (en) 2013-05-01

Family

ID=40229517

Family Applications (1)

Application Number Title Priority Date Filing Date
EP08826293.6A Not-in-force EP2173793B1 (en) 2007-07-10 2008-08-26 Masterbatch preparation process

Country Status (8)

Country Link
US (1) US8481614B2 (en)
EP (1) EP2173793B1 (en)
CN (1) CN101790557B (en)
AU (1) AU2008274913B2 (en)
ES (1) ES2421889T3 (en)
PL (1) PL2173793T3 (en)
WO (1) WO2009009808A2 (en)
ZA (1) ZA201000174B (en)

Families Citing this family (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB201403057D0 (en) * 2014-02-21 2014-04-09 Addivant Switzerland Gmbh Process
DE102015000262A1 (en) * 2015-01-16 2016-07-21 Sandvik Tps Zweigniederlassung Der Sandvik Materials Technology Deutschland Gmbh Process for producing a thermoplastic granulate
WO2018213855A1 (en) * 2017-05-15 2018-11-22 Lionel Mantzivis A process for preparing a masterbatch and a masterbatch
WO2020028925A1 (en) * 2018-07-30 2020-02-06 Lionel Nicholas Mantzivis Masterbatch preparation process
FR3095341B1 (en) * 2019-04-26 2021-05-14 Miyoshi Europe COMPOUND CONSISTING OF A FUNCTIONAL AGENT AND A WAX DIE INCLUDING AN ORGANOSILICIAL MATERIAL, AND RELATED MANUFACTURING PROCESS

Family Cites Families (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2654979B2 (en) 1988-10-15 1997-09-17 住友化学工業株式会社 Pigment masterbatch for filler-containing polypropylene composition
WO2001044387A2 (en) 1999-12-13 2001-06-21 Basf Aktiengesellschaft Pigment concentrates and methods for production thereof
AU2002213839A1 (en) 2000-11-27 2002-06-03 Anders Flensburg High pigment/additive concentration polymer granulate
DE10345647A1 (en) * 2003-10-01 2005-04-21 Merck Patent Gmbh Pigment preparation for plastics
DE102004048098A1 (en) 2004-09-29 2006-04-06 Grafe Color Batch Gmbh Highly concentrated and finely dispersed additive masterbatches in granular form
US20070100056A1 (en) * 2005-10-31 2007-05-03 Mitsui Chemicals, Inc. Process for producing thermoplastic resin composition
DE102006049090A1 (en) 2006-10-18 2008-04-30 Clariant International Limited Uploaded adhesive composition through the use of metallocene waxes

Non-Patent Citations (1)

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Title
See references of WO2009009808A2 *

Also Published As

Publication number Publication date
WO2009009808A8 (en) 2009-06-25
PL2173793T3 (en) 2013-09-30
US20100261810A1 (en) 2010-10-14
AU2008274913B2 (en) 2013-10-17
WO2009009808A2 (en) 2009-01-15
ES2421889T3 (en) 2013-09-06
AU2008274913A1 (en) 2009-01-15
ZA201000174B (en) 2010-09-29
CN101790557B (en) 2012-10-10
US8481614B2 (en) 2013-07-09
WO2009009808A3 (en) 2009-03-12
EP2173793B1 (en) 2013-05-01
CN101790557A (en) 2010-07-28

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